Small-size high-voltage output high-power DC / DC power supply module

Abstract

The utility model discloses a small-size high-voltage output high-power DC / DC power supply module, which comprises an auxiliary power supply circuit, a low-voltage-to-high-voltage DC / DC power conversion circuit, an output constant current and short circuit protection circuit, an output filter circuit and a voltage stabilizing circuit, the low-voltage-to-high-voltage DC / DC power conversion circuit adopts a forward active clamping quasi-resonant soft switching circuit, an input direct-current voltage is converted into a high-frequency alternating-current voltage through a main power switch tube, then the high-frequency alternating-current voltage is coupled to a secondary unit through a high-frequency transformer, the secondary unit adopts a two-path series connection mode to achieve high-voltage output, isolation conversion is achieved, and the high-frequency alternating-current voltage is output through a high-frequency transformer. And the output voltage signal is fed back to the control end of the controller through the feedback control circuit, so that the duty ratio of the driving square wave signal is adjusted, and the stability of the output voltage is realized. The power supply is a modularized power supply with low-voltage input and high-voltage high-power output, has the characteristics of small size, strong interchangeability, high efficiency, high reliability and the like, and can meet the requirements of low-voltage input and high-voltage output high-power DC / DC power supply occasions.

Description

Technical Field

[0001] The utility model relates to the field of power supply circuits, in particular to a small-volume, high-voltage output and high-power DC / DC power supply module. Background Art

[0002] Traditional high-power power supplies with low-voltage input and high-voltage output are basically implemented by connecting several modules (or discrete devices) in series. This is not only large in size, but also requires a large number of external components, has low efficiency, poor EMI performance, and is extremely costly. With the current market requirements for green energy saving and the transformation of equipment miniaturization, traditional power supply designs are difficult to adapt to market demand. Therefore, DC / DC integrated power supply modules with small size, high-voltage output and high power have completely solved this problem, and the market demand is very broad. Utility Model Content

[0003] The utility model is a small-volume, high-voltage, high-power DC / DC power supply module designed to solve the above technical problems.

[0004] The technical solution adopted by the utility model to solve its technical problems is:

[0005] A small-volume, high-voltage, high-power DC / DC power module comprises an auxiliary power supply circuit, a low-voltage to high-voltage DC / DC power conversion circuit, an output constant current and short-circuit protection circuit, an output filter circuit and a voltage stabilizing circuit; the low-voltage to high-voltage DC / DC power conversion circuit adopts a forward active clamp quasi-resonant soft switching circuit to convert an input DC voltage (+Vin, -Vin) into a high-frequency AC voltage through a main power switch tube, and then couples to a secondary through a high-frequency transformer; the secondary adopts a two-way series connection to achieve high-voltage output and isolated conversion; the output voltage signal is fed back to the control end of a controller through a feedback control circuit to adjust the duty cycle of a driving square wave signal and achieve output voltage stability; at the same time, the output voltage outputs a high-voltage DC power supply (+Vo, -Vo) through the output constant current and short-circuit protection circuit, the output filter circuit and the voltage stabilizing circuit.

[0006] The present invention relates to a small-volume, high-voltage, high-power DC / DC power supply module. The forward active clamping quasi-resonant soft switching circuit is composed of a PWM controller U1 and its auxiliary circuits. The PWM controller U1 uses an LM5025BMTC chip. The input end of the power supply module is connected to the 7th pin (Vcc end) of the PWM controller U1 through an auxiliary power supply circuit. At the same time, the input DC voltage (+Vin) is connected to the primary ends of the main transformers T3 and T4 respectively. The primary ends of the main transformers T3 and T4 are connected to the primary ends of the current-sensing transformers T1 and T2. The primary ends of T1 and T2 are connected to the main power switch. The drains of the switch tubes Q1 and Q2 are connected, and the gates of the main power switch tubes Q1 and Q2 are connected to the 8th pin (OUT-A terminal) of the PWM controller U1 through the resistor R17 and the driver chip U2. At the same time, the diode D3 is connected in parallel with the resistor R17, and the anode of the diode D3 is connected to the gates of the main power switch tubes Q1 and Q2; the source of the main power switch tubes Q1 and Q2 is connected to the ground, and the drains of the main power switch tubes Q1 and Q2 are connected to the drain of the field effect tube Q3 through the parallel clamping capacitors C15, C16, and C17. The gate of the field effect tube Q3 is connected to the resistor R19, the capacitor C20, and the driver chip U3. Then it is connected to the 9th pin (OUT-B terminal) of the PWM controller U1, the source of the field effect tube Q3 is connected to the ground, the 1st pin (VIN terminal) of the PWM controller U1 is suspended, the 2nd pin (RAMP terminal) of the PWM controller U1 is connected to the external RC slope compensation circuit of the input DC voltage, the 3rd pin (CS1 terminal) of the PWM controller U1 is connected to the sampling current limiting circuit, the 4th pin (CS2 terminal) of the PWM controller U1 is connected to the ground, the 5th pin (TIME terminal) of the PWM controller U1 is connected to the external dead time setting resistor, and the 6th pin (REF terminal) of the PWM controller U1 is connected to the external base The PWM controller U1 is connected to the quasi-circuit, pin 10 (PGND terminal) of the PWM controller U1 is connected to the ground, pin 11 (AGND terminal) of the PWM controller U1 is connected to the ground, pin 12 (SS terminal) of the PWM controller U1 is connected to the soft start circuit, pin 13 (COMP terminal) of the PWM controller U1 is connected to the collectors of the optocouplers U5 and U6, pin 14 (RT terminal) of the PWM controller U1 is connected to the timing circuit, pin 15 (SYNC terminal) of the PWM controller U1 is connected to the clock synchronization circuit, and pin 16 (UVLO terminal) of the PWM controller U1 is connected to the input undervoltage protection circuit.

[0007] The invention discloses a small-volume, high-voltage, high-power DC / DC power supply module, wherein the specific connection mode of the two-way series connection mode is as follows: the head of the secondary of the main transformer T3 is connected to the anode of the rectifier diode D8, the cathode of the rectifier diode D8 is connected to the cathode of the freewheeling diode D9, and is also connected to the output +Vo terminal; the tail of the secondary of the main transformer T3 is connected to the anode of the freewheeling diode D9, and is also connected to one end of the energy storage inductor L1; the other end of the energy storage inductor L1 is connected to the cathode of the rectifier diode D10, and is also connected to the cathode of the freewheeling diode D11; the head of the secondary of the main transformer T4 is connected to the anode of the rectifier diode D10, the tail of the secondary of the main transformer T4 is connected to the anode of the freewheeling diode D11, and is also connected to one end of the energy storage inductor L2; the other end of the energy storage inductor L2 is connected to the output -Vo terminal through the sampling resistor R30.

[0008] The small-volume, high-voltage, high-power DC / DC power supply module, the feedback control circuit includes a sampling resistor R30, an output sampling protection circuit, and photoelectric couplers U5 and U6; the input end of the output sampling protection circuit is connected across the sampling resistor R30, and the output sampling protection circuit outputs a feedback signal through the collectors of the photoelectric couplers U5 and U6.

[0009] In the small-volume, high-voltage, high-power DC / DC power supply module, the driver chips U2 and U3 both use chips with model number UCC27324DGN.

[0010] The invention discloses a small-volume, high-voltage, high-power DC / DC power supply module, wherein the input DC voltage (+Vin, -Vin) of the power supply module ranges from DC20 to 50V, the output high-voltage DC power (+Vo, -Vo) is DC330V 400W, and the module has an integrated design; the input and output of the power supply module are isolated, and the isolation voltage can reach AC1500V.

[0011] In the small-volume, high-voltage, high-power DC / DC power supply module, the diodes D8, D9, D10 and D11 are all made of silicon carbide, which ensures high-voltage output while also meeting the requirements of reverse recovery time and derating design, further ensuring high module efficiency.

[0012] In the small-volume, high-voltage, high-power DC / DC power supply module, the transformers T1, T2, T3 and T4 are all wound with three-layer insulated wires in the order of primary, secondary, and primary.

[0013] The small-volume, high-voltage, high-power DC / DC power supply module has four mounting holes, and the input and output ends are in the form of pins. The module can be directly plugged into a PCB board and installed and fixed for use, and has a volume of 86*83*13mm.

[0014] The small-volume, high-voltage, high-power DC / DC power supply module has a power module housing structure that uses a plastic-sealed housing that is bonded to a power base plate to achieve an integrated structure.

[0015] The utility model has the following advantages:

[0016] 1. The overall height of the power module is 13 mm, which meets the trend of low profile and has the characteristics of small size, high power, low cost and strong interchangeability;

[0017] 2. The power module has a low input voltage (DC20-50V), a high output voltage (DC330V) 400W, and an efficiency of up to 90%;

[0018] 3. The power module is an integrated design. The power module requires few components outside and the overall cost is very low. The integration and optimization of the circuit can further improve the EMI performance.

[0019] 4. The input and output of the power module are isolated, and the isolation voltage can reach AC1500V without breakdown and sparking;

[0020] 5. Standardized and serialized product design meets the parameter requirements of low voltage input, high voltage output and high power, with wider adaptability and better performance.

[0021] The beneficial effects of the utility model are: using the forward active clamping quasi-resonant soft switching technology, the input DC voltage is converted into a high-frequency AC voltage through the main power switch tube, and then coupled to the secondary through a high-frequency transformer. The secondary adopts a two-way series connection to achieve high-voltage output, which can achieve isolated transformation. The output voltage signal is fed back to the control end of the controller through the feedback control circuit to adjust the duty cycle of the driving square wave signal and achieve output voltage stability. The module adopts an integrated design method, which greatly reduces the cost while reducing the number of external components and improves the reliability of the power module. The power module has a mounting hole, and the input and output ends are pin-leading, which can be directly plugged into the PCB board and installed and fixed for use. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is the schematic diagram of the power module of the utility model;

[0023] Figure 2 It is a schematic diagram of the structure of the utility model. DETAILED DESCRIPTION

[0024] The utility model is further described below in conjunction with the accompanying drawings and embodiments.

[0025] like Figure 1As shown, the utility model is a small-volume high-voltage output high-power DC / DC power supply module, comprising an auxiliary power supply circuit, a low-voltage to high-voltage DC / DC power conversion circuit, an output constant current and short-circuit protection circuit, an output filter circuit and a voltage stabilizing circuit; the low-voltage to high-voltage DC / DC power conversion circuit adopts a forward active clamp quasi-resonant soft switching circuit to convert the input DC voltage (+Vin, -Vin) into a high-frequency AC voltage through a main power switch tube, and then couples to the secondary through a high-frequency transformer. The secondary adopts a two-way series connection method to achieve high-voltage output and isolated conversion. The output voltage signal is fed back to the control end of the controller through a feedback control circuit to adjust the duty cycle of the driving square wave signal and achieve output voltage stability; at the same time, the output voltage outputs a high-voltage DC power supply (+Vo, -Vo) through the output constant current and short-circuit protection circuit, the output filter circuit and the voltage stabilizing circuit.

[0026] A small-volume, high-voltage, high-power DC / DC power supply module, wherein the forward active clamp quasi-resonant soft switching circuit is composed of a PWM controller U1 and its auxiliary circuit; the PWM controller U1 uses an LM5025BMTC chip, the input end of the power supply module is connected to the 7th pin (Vcc end) of the PWM controller U1 through an auxiliary power supply circuit, and the input DC voltage (+Vin) is respectively connected to the primary heads of the main transformers T3 and T4, the primary tails of the main transformers T3 and T4 are connected to the primary heads of the current-detecting transformers T1 and T2, the primary tails of T1 and T2 are connected to the drains of the main power switches Q1 and Q2, the gates of the main power switches Q1 and Q2 are connected to the 8th pin (OUT-A end) of the PWM controller U1 through the resistor R17 and the driver chip U2, and at the same time, the diode D3 is connected in parallel with the resistor R17, and the anode of the diode D3 is connected to the gates of the main power switches Q1 and Q2; The source of the main power switch tubes Q1 and Q2 is connected to the ground, and the drain of the main power switch tubes Q1 and Q2 is connected to the drain of the field effect tube Q3 through the parallel clamping capacitors C15, C16, and C17. The gate of the field effect tube Q3 is connected to the 9th pin (OUT-B terminal) of the PWM controller U1 through the resistor R19, the capacitor C20, and the driver chip U3. The source of the field effect tube Q3 is connected to the ground, the 1st pin (VIN terminal) of the PWM controller U1 is suspended, the 2nd pin (RAMP terminal) of the PWM controller U1 is connected to the external RC slope compensation circuit of the input DC voltage, the 3rd pin (CS1 terminal) of the PWM controller U1 is connected to the sampling current limiting circuit, the 4th pin (CS2 terminal) of the PWM controller U1 is connected to the ground, and the PWM controller U Pin 5 (TIME terminal) of PWM controller U1 is connected to the external dead time setting resistor, pin 6 (REF terminal) of PWM controller U1 is connected to the external reference circuit, pin 10 (PGND terminal) of PWM controller U1 is connected to ground, pin 11 (AGND terminal) of PWM controller U1 is connected to ground, pin 12 (SS terminal) of PWM controller U1 is connected to the soft start circuit, pin 13 (COMP terminal) of PWM controller U1 is connected to the collector of optocouplers U5 and U6, pin 14 (RT terminal) of PWM controller U1 is connected to the timing circuit, pin 15 (SYNC terminal) of PWM controller U1 is connected to the clock synchronization circuit, and pin 16 (UVLO terminal) of PWM controller U1 is connected to the input undervoltage protection circuit.

[0027] The power module uses the internationally advanced forward active clamp quasi-resonant soft switching technology, and through circuit integration and optimization, the module maintains a very high efficiency (efficiency can reach 90%). It adopts a small volume, high voltage output, high power DC / DC integrated power module integrated design, breaking through the traditional series connection of multiple modules (or discrete devices) to achieve a high voltage output design.

[0028] The invention discloses a small-volume, high-voltage, high-power DC / DC power supply module, wherein the specific connection mode of the two-way series connection mode is as follows: the head of the secondary of the main transformer T3 is connected to the anode of the rectifier diode D8, the cathode of the rectifier diode D8 is connected to the cathode of the freewheeling diode D9, and is also connected to the output +Vo terminal; the tail of the secondary of the main transformer T3 is connected to the anode of the freewheeling diode D9, and is also connected to one end of the energy storage inductor L1; the other end of the energy storage inductor L1 is connected to the cathode of the rectifier diode D10, and is also connected to the cathode of the freewheeling diode D11; the head of the secondary of the main transformer T4 is connected to the anode of the rectifier diode D10, the tail of the secondary of the main transformer T4 is connected to the anode of the freewheeling diode D11, and is also connected to one end of the energy storage inductor L2; the other end of the energy storage inductor L2 is connected to the output -Vo terminal through the sampling resistor R30.

[0029] The small-volume, high-voltage, high-power DC / DC power supply module, the feedback control circuit includes a sampling resistor R30, an output sampling protection circuit, and photoelectric couplers U5 and U6; the input end of the output sampling protection circuit is connected across the sampling resistor R30, and the output sampling protection circuit outputs a feedback signal through the collectors of the photoelectric couplers U5 and U6.

[0030] In the small-volume, high-voltage, high-power DC / DC power supply module, the driver chips U2 and U3 both use chips with model number UCC27324DGN.

[0031] The invention discloses a small-volume, high-voltage, high-power DC / DC power supply module, wherein the input DC voltage (+Vin, -Vin) of the power supply module ranges from DC20 to 50V, the output high-voltage DC power (+Vo, -Vo) is DC330V 400W, and the module has an integrated design; the input and output of the power supply module are isolated, the isolation voltage can reach AC1500V, and there is no breakdown or sparking.

[0032] In the small-volume, high-voltage, high-power DC / DC power supply module, the diodes D8, D9, D10 and D11 are all made of silicon carbide, which ensures high-voltage output while also meeting the requirements of reverse recovery time and derating design, further ensuring high module efficiency.

[0033] In the small-volume, high-voltage, high-power DC / DC power supply module, the transformers T1, T2, T3 and T4 are all wound with three-layer insulated wires with good insulation performance, and the winding sequence is primary, secondary, and primary. While ensuring isolation and withstand voltage, the transformer is fully coupled, which greatly improves the reliability of the transformer when the secondary high voltage works.

[0034] The small-volume, high-voltage, high-power DC / DC power supply module has four mounting holes, and the input and output ends are in the form of pins. It can be directly plugged into a PCB board and installed and fixed for use. The volume is 86*83*13mm (excluding the pin height).

[0035] The small-volume, high-voltage, high-power DC / DC power supply module has a housing structure that uses a plastic-sealed housing and is bonded to a power base plate to achieve an integrated structure, and has the characteristics of light weight and low cost.

[0036] Its dimensions are shown in Figure 2 .

[0037] The present utility model is not limited to the above-mentioned optimal implementation mode. Any other products identical or similar to the present utility model derived by anyone under the inspiration of the present utility model shall fall within the protection scope of the present utility model.

Claims

1. A small-volume, high-voltage, high-power DC / DC power module, comprising an auxiliary power supply circuit, a low-voltage to high-voltage DC / DC power conversion circuit, an output constant current and short-circuit protection circuit, an output filter circuit and a voltage stabilization circuit; characterized in that: The low-voltage to high-voltage DC / DC power conversion circuit adopts a forward active clamp quasi-resonant soft switching circuit to convert the input DC voltage (+Vin, -Vin) into a high-frequency AC voltage through a main power switch tube, and then couples it to the secondary through a high-frequency transformer. The secondary adopts a two-way series connection method to achieve high-voltage output and isolated conversion. The output voltage signal is fed back to the control end of the controller through a feedback control circuit to adjust the duty cycle of the driving square wave signal and achieve output voltage stability; at the same time, the output voltage outputs a high-voltage DC power supply (+Vo, -Vo) through an output constant current and short-circuit protection circuit, an output filter circuit and a voltage stabilization circuit.

2. A small-volume, high-voltage, high-power DC / DC power supply module according to claim 1, characterized in that: The forward active clamp quasi-resonant soft switching circuit is composed of a PWM controller U1 and its auxiliary circuit; the PWM controller U1 uses the LM5025BMTC chip, the input end of the power module is connected to the 7th pin (Vcc) of the PWM controller U1 through the auxiliary power supply circuit, and the input DC voltage (+Vin) is connected to the primary ends of the main transformers T3 and T4 respectively, the primary ends of the main transformers T3 and T4 are connected to the primary ends of the current detection transformers T1 and T2, the primary ends of T1 and T2 are connected to the drains of the main power switches Q1 and Q2, and the main power The gates of the power switches Q1 and Q2 are connected to the 8th pin (OUT-A) of the PWM controller U1 through the resistor R17 and the driver chip U2. At the same time, the diode D3 is connected in parallel with the resistor R17, and the anode of the diode D3 is connected to the gates of the main power switches Q1 and Q2; the sources of the main power switches Q1 and Q2 are connected to the ground, and the drains of the main power switches Q1 and Q2 are connected to the drain of the field effect tube Q3 through the parallel clamping capacitors C15, C16, and C17. The gate of the field effect tube Q3 is connected to the PWM controller U1 through the resistor R19, the capacitor C20, and the driver chip U3. The 9th pin (OUT-B) of the PWM controller U1 is connected, the source of the field effect tube Q3 is connected to the ground, the 1st pin (VIN) of the PWM controller U1 is suspended, the 2nd pin (RAMP) of the PWM controller U1 is connected to the external RC slope compensation circuit of the input DC voltage, the 3rd pin (CS1) of the PWM controller U1 is connected to the sampling current limiting circuit, the 4th pin (CS2) of the PWM controller U1 is connected to the ground, the 5th pin (TIME) of the PWM controller U1 is connected to the external dead time setting resistor, and the 6th pin (REF) of the PWM controller U1 is connected to the external reference circuit. The pin 10 (PGND) of the PWM controller U1 is connected to the ground, the pin 11 (AGND) of the PWM controller U1 is connected to the ground, the pin 12 (SS) of the PWM controller U1 is connected to the soft start circuit, the pin 13 (COMP) of the PWM controller U1 is connected to the collectors of the optocouplers U5 and U6, the pin 14 (RT) of the PWM controller U1 is connected to the timing circuit, the pin 15 (SYNC) of the PWM controller U1 is connected to the clock synchronization circuit, and the pin 16 (UVLO) of the PWM controller U1 is connected to the input undervoltage protection circuit.

3. The small-volume, high-voltage, high-power DC / DC power supply module according to claim 1, characterized in that: The specific connection method of the two-way series connection is: the head of the secondary of the main transformer T3 is connected to the anode of the rectifier diode D8, the cathode of the rectifier diode D8 is connected to the cathode of the freewheeling diode D9, and is also connected to the output +Vo terminal, the tail of the secondary of the main transformer T3 is connected to the anode of the freewheeling diode D9, and is also connected to one end of the energy storage inductor L1, and the other end of the energy storage inductor L1 is connected to the cathode of the rectifier diode D10, and is also connected to the cathode of the freewheeling diode D11; the head of the secondary of the main transformer T4 is connected to the anode of the rectifier diode D10, the tail of the secondary of the main transformer T4 is connected to the anode of the freewheeling diode D11, and is also connected to one end of the energy storage inductor L2, and the other end of the energy storage inductor L2 is connected to the output -Vo terminal through the sampling resistor R30.

4. The small-volume, high-voltage, high-power DC / DC power supply module according to claim 1, characterized in that: The feedback control circuit includes a sampling resistor R30, an output sampling protection circuit, and photoelectric couplers U5 and U6; the input end of the output sampling protection circuit is connected across the sampling resistor R30, and the output sampling protection circuit outputs a feedback signal through the collectors of the photoelectric couplers U5 and U6.

5. The small-volume, high-voltage, high-power DC / DC power supply module according to claim 1, characterized in that: Driver chips U2 and U3 both use chips with model number UCC27324DGN.

6. The small-volume, high-voltage, high-power DC / DC power supply module according to claim 1, characterized in that: The input DC voltage (+Vin, -Vin) range of the power module is DC20-50V, and the output high-voltage DC power (+Vo, -Vo) is DC330V 400W. The module has an integrated design. The input and output of the power module are isolated, and the isolation voltage can reach AC1500V.

7. The small-volume, high-voltage, high-power DC / DC power supply module according to claim 1, characterized in that: Diodes D8, D9, D10 and D11 are all made of silicon carbide.

8. The small-volume, high-voltage, high-power DC / DC power supply module according to claim 1, characterized in that: The transformers T1, T2, T3 and T4 are all wound with three-layer insulated wires, and the winding sequence is primary, secondary, and primary.

9. The small-volume, high-voltage, high-power DC / DC power supply module according to claim 1, characterized in that: The power module has 4 mounting holes, and the input and output ends are pin-type, so it can be directly plugged into the PCB board and installed and fixed for use, and the volume is 86*83*13mm.

10. The small-volume, high-voltage, high-power DC / DC power supply module according to claim 1, characterized in that: The power module housing structure adopts a plastic-sealed housing, which is bonded to the power base plate to achieve an integrated structure.

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